US8790618B2 - Systems and methods for initiating operation of pressure swing adsorption systems and hydrogen-producing fuel processing systems incorporating the same - Google Patents

Systems and methods for initiating operation of pressure swing adsorption systems and hydrogen-producing fuel processing systems incorporating the same Download PDF

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US8790618B2
US8790618B2 US12/963,530 US96353010A US8790618B2 US 8790618 B2 US8790618 B2 US 8790618B2 US 96353010 A US96353010 A US 96353010A US 8790618 B2 US8790618 B2 US 8790618B2
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hydrogen
psa
assembly
hpr
stream
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US20110150756A1 (en
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Patton M. Adams
James A. Givens
Arne LaVen
Sudha Rani Laven
Curtiss Renn
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Naval Group SA
Idatech LLC
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DCNS SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/047—Pressure swing adsorption
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    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
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    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/50—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
    • C01B3/56—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/16—Hydrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/40001—Methods relating to additional, e.g. intermediate, treatment of process gas
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/40007—Controlling pressure or temperature swing adsorption
    • C—CHEMISTRY; METALLURGY
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    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/02—Processes for making hydrogen or synthesis gas
    • C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
    • C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/02—Processes for making hydrogen or synthesis gas
    • C01B2203/025—Processes for making hydrogen or synthesis gas containing a partial oxidation step
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/02—Processes for making hydrogen or synthesis gas
    • C01B2203/0283—Processes for making hydrogen or synthesis gas containing a CO-shift step, i.e. a water gas shift step
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    • C01B2203/0405—Purification by membrane separation
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/042—Purification by adsorption on solids
    • C01B2203/043—Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0435—Catalytic purification
    • C01B2203/044—Selective oxidation of carbon monoxide
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0435—Catalytic purification
    • C01B2203/0445—Selective methanation
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    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0465—Composition of the impurity
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0465—Composition of the impurity
    • C01B2203/0475—Composition of the impurity the impurity being carbon dioxide
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0465—Composition of the impurity
    • C01B2203/048—Composition of the impurity the impurity being an organic compound
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0465—Composition of the impurity
    • C01B2203/0495—Composition of the impurity the impurity being water
    • C—CHEMISTRY; METALLURGY
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    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/06—Integration with other chemical processes
    • C01B2203/066—Integration with other chemical processes with fuel cells

Definitions

  • the present disclosure is directed generally to pressure swing adsorption systems and hydrogen-generation and/or fuel cell systems incorporating the same, and more particularly to such systems and to methods that reduce the startup time of pressure swing adsorption systems.
  • the product stream from a hydrogen-generation assembly may contain impurities, illustrative, non-exclusive examples of which include one or more of carbon monoxide, carbon dioxide, methane, unreacted feedstock, and water. Therefore, there is a need in many conventional fuel cell systems to include suitable structure for removing impurities from the product hydrogen stream.
  • a pressure swing adsorption (PSA) process is an illustrative, non-exclusive example of a mechanism that may be used to remove impurities from an impure hydrogen gas stream by selective adsorption of one or more of the impurities present in the impure hydrogen stream, The adsorbed impurities can be subsequently desorbed and removed from the PSA assembly.
  • PSA is a pressure-driven separation process that utilizes a plurality of adsorbent beds. The beds are cycled through a series of steps, such as one or more pressurization, separation (adsorption), equalization, depressurization (desorption), and/or purge steps to selectively remove impurities from the hydrogen gas and then desorb the impurities.
  • An energy-producing assembly is a combination of a hydrogen-generation assembly, PSA assembly, fuel cell, and related system components.
  • Energy-producing assemblies are used to produce some form of usable energy, such as electrical or thermal energy.
  • the energy-producing assembly is used to supply backup power to an energy-consuming device when the primary power source becomes unavailable, reducing the startup time of the energy-producing assembly may be critical to ensuring the continued operation of the energy-consuming device.
  • the present disclosure is directed to systems for optimized startup of PSA assemblies, as well as to energy-producing assemblies, hydrogen-generation assemblies, and/or fuel cell systems containing the same, and to methods of operating the same.
  • the PSA assemblies include at least one adsorbent bed, and typically a plurality of adsorbent beds, that include an adsorbent region including adsorbent adapted to remove impurities from a mixed gas stream containing hydrogen gas as a majority component and other gases.
  • the mixed gas stream may be produced by a hydrogen-producing region of a fuel processing system, and the PSA assembly may produce a product hydrogen stream from the mixed gas stream.
  • the product hydrogen stream may be consumed by a fuel cell stack to provide a fuel cell system that produces electrical power.
  • FIG. 1 is a schematic view of an illustrative, non-exclusive example of an energy-producing and consuming assembly that includes a hydrogen-generation assembly with an associated feedstock delivery system and a fuel processing system, as well as a fuel cell stack and an energy-consuming device.
  • FIG. 2 is a schematic view of a hydrogen-producing assembly in the form of a steam reformer adapted to produce a reformate stream containing hydrogen gas and other gases from water and at least one carbon-containing feedstock.
  • FIG. 4 is a schematic view of a pressure swing adsorption assembly that includes optional inputs from a stored hydrogen source according to the present disclosure.
  • FIG. 5 is a schematic cross-sectional view of an illustrative, non-exclusive example of an adsorbent bed construction that may be used with PSA assemblies according to the present disclosure.
  • FIG. 6 is a schematic cross-sectional view of an illustrative, non-exclusive example of an adsorbent bed construction that may be used with PSA assemblies according to the present disclosure.
  • FIG. 7 is a schematic cross-sectional view of an illustrative, non-exclusive example of an adsorbent bed construction that may be used with PSA assemblies according to the present disclosure.
  • FIG. 8 is an illustrative, non-exclusive example of a timeline schematically representing the total time required to startup a hydrogen-generation assembly in the instance where startup of the reformer and the PSA assembly are commenced in series (top), in the instance where startup of the reformer and the PSA assembly are commenced in parallel (middle), and in the instance where the startup of the PSA assembly is at least partially concurrent with the startup of the reformer (bottom).
  • FIG. 9 is a flowchart depicting an illustrative, non-exclusive example of an overall operating sequence that may be used with PSA assemblies according to the present disclosure.
  • FIG. 10 is a flowchart representing an illustrative, non-exclusive example of a shutdown sequence that places a PSA assembly in a depressurized dormant state that may be used according to the present disclosure.
  • FIG. 11 is a flowchart representing an illustrative, non-exclusive example of a shutdown sequence that places a PSA assembly in a pressurized dormant state that may be used according to the present disclosure.
  • FIG. 12 is a flowchart representing an illustrative, non-exclusive example of a shutdown cycle sequence that may be used to clean adsorbents from a PSA bed prior to system shutdown according to the present disclosure.
  • FIG. 13 is a flowchart representing an illustrative, non-exclusive example of a startup cycle sequence that may be used to clean adsorbents from a PSA bed during system startup according to the present disclosure.
  • FIG. 14 is a schematic view of the stream flows that may be associated with a PSA assembly according to the present disclosure while the PSA assembly is in a startup state.
  • FIG. 1 illustrates schematically an illustrative, non-exclusive example of an energy-producing and consuming assembly 56 .
  • Energy-producing and consuming assembly 56 includes an energy-producing system 22 and at least one energy-consuming device 52 adapted to exert an applied load on energy-producing system 22 .
  • energy-producing system 22 includes a fuel cell stack 24 and a hydrogen-generation assembly 46 . More than one of any of the illustrated components may be used without departing from the scope of the present disclosure.
  • System 22 also may be referred to as a fuel cell system and/or a hydrogen-producing fuel cell system.
  • hydrogen-generation assemblies and/or fuel cell systems include a separation assembly 72 that includes at least one pressure swing adsorption (PSA) assembly 73 that is adapted to increase the purity of the hydrogen gas that is produced in the hydrogen-generation assembly and/or delivered for consumption in the fuel cell stack to produce an electrical output.
  • PSA pressure swing adsorption
  • gaseous impurities are removed from a stream containing hydrogen gas as a majority component, as well as other gases as minority components.
  • PSA is based on the principle that certain gases, under the proper conditions of temperature and pressure, will be adsorbed onto an adsorbent material more strongly than other gases.
  • impurities may thereafter be desorbed and removed, such as in the form of a byproduct stream.
  • PSA common impurity gases
  • Hydrogen gas adsorbs only very weakly and so hydrogen gas passes through the adsorbent bed while the impurities are retained on the adsorbent material.
  • Illustrative, non-exclusive examples of suitable mechanisms for producing hydrogen gas from feedstock supply stream(s) 68 in hydrogen-producing region 70 include steam reforming and autothermal reforming, in which reforming catalysts are used to produce hydrogen gas from a feedstock supply stream 68 containing water and at least one carbon-containing feedstock.
  • Other illustrative, non-exclusive examples of suitable mechanisms for producing hydrogen gas include pyrolysis and catalytic partial oxidation of a carbon-containing feedstock, in which case feedstock supply stream 68 does not contain water.
  • Still another suitable mechanism for producing hydrogen gas is electrolysis, in which case the feedstock is water.
  • Illustrative, non-exclusive examples of suitable carbon-containing feedstocks include at least one hydrocarbon or alcohol.
  • the byproduct stream may have sufficient fuel value (i.e., hydrogen gas and/or other combustible gas content) to enable the heating assembly, when present, to maintain the hydrogen-producing region at a desired operating temperature or within a selected range of such temperatures.
  • These temperatures may be referred to as hydrogen-producing temperatures and refer to a range of temperatures in which the hydrogen-producing region efficiently produces hydrogen gas from the feedstock supply stream(s).
  • the hydrogen-producing temperatures may include a minimum hydrogen-producing temperature and a maximum hydrogen-producing temperature. These temperatures may be selected, or determined, by such factors as the catalyst being used, the feedstock(s) being used the configuration of the hydrogen-producing region, etc.
  • storage device 62 also may be in fluid communication with PSA assembly 73 via PSA hydrogen delivery stream 43 .
  • hydrogen gas that was stored in storage device 62 may be delivered to the PSA assembly, such as for use to pressurize one or more adsorbent beds of the PSA assembly and/or as a purge stream for the PSA assembly.
  • this hydrogen gas from the storage device may have been previously produced in the hydrogen-producing region and/or purified in the PSA assembly.
  • Storage device 62 may be any suitable device for storing hydrogen gas produced by fuel processing system 64 .
  • suitable storage devices 62 include metal hydride beds, tanks or other suitable pressure vessels for storing hydrogen gas, and adsorption beds containing other hydrogen-adsorbing materials such as sodium alanate, carbon nanotubes, or metal-organic polymers.
  • suitable metal hydrides include LaNi 5 and other alloys of lanthanum and nickel. The hydride and adsorption beds will typically include a pressure vessel that contains the metal hydride or adsorbent.
  • the system may be designed to optimize heat transfer to and from the metal hydride alloy such that heat can be delivered to the hydride bed at a rate sufficient to produce the desired flow rate of hydrogen from the hydride bed and removed from the bed at a rate sufficient to allow for the desired hydrogen absorption rate.
  • the hydride bed may include optimized heat transfer structures, illustrative, non-exclusive examples of which include, but are not limited to, internal or external fins, metal brushes, water pipes, heat pipes, air tubes, thermal ballast, or other heat transfer means.
  • the sources of heat may include, separately or in combination, electricity (such as in the form of a resistance heater or other electrically powered heat source), fuel cell stack exhaust, reformer exhaust, fuel cell stack coolant, hot air from a cabinet heater, energy stored as heat in the fuel processor or fuel cell system components, or heat from any other suitable source or process.
  • the at least one energy-consuming device 52 may be electrically coupled to energy-producing system 22 , such as to fuel cell stack 24 and/or one or more energy-storage devices 78 associated with the stack.
  • Device 52 applies a load to energy-producing system 22 and draws an electric current from the system to satisfy the load.
  • This load may be referred to as an applied load, and may include thermal and/or electrical load(s). It is within the scope of the present disclosure that the applied load may be satisfied by the fuel cell stack, the energy-storage device, or both the fuel cell stack and the energy-storage device.
  • the mixed gas stream flows through the adsorbent region, carbon monoxide, carbon dioxide, water and/or other ones of the impurities, or other gases, are adsorbed, and thereby at least temporarily retained, on the adsorbent. This is because these gases are more readily adsorbed on the selected adsorbents used in the PSA assembly.
  • the remaining portion of the mixed gas stream which now may perhaps more accurately be referred to as a purified hydrogen stream, passes through the bed and is exhausted from the other end of the bed.
  • hydrogen gas may be described as being the less readily adsorbed component, while carbon monoxide, carbon dioxide, etc. may be described as the more readily adsorbed components of the mixed gas stream.
  • the pressure of the product hydrogen stream is typically reduced prior to utilization of the gas by the fuel cell stack.
  • the desorption step often includes selectively decreasing the pressure within the adsorbent region through the withdrawal of gas, typically in a countercurrent direction relative to the feed direction.
  • This desorption step also may be referred to as a depressurization, or blowdown, step.
  • This step often includes or is performed in conjunction with the use of a purge gas stream, which is typically delivered in a countercurrent flow direction to the direction at which the mixed gas stream flows through the adsorbent region.
  • this desorption step may include drawing an at least partial vacuum on the bed, but this is not required. While also not required, it is often desirable to utilize one or more equalization steps, in which two or more beds are fluidly interconnected to permit the beds to equalize the relative pressures therebetween. For example, one or more equalization steps may precede the desorption and pressurization steps. Prior to the desorption step, equalization is used to reduce the pressure in the bed and to recover some of the purified hydrogen gas contained in the bed, while prior to the (re)pressurization step, equalization is used to increase the pressure within the bed. Equalization may be accomplished using concurrent and/or countercurrent flow of gas. After the desorption and/or purge step(s) of the desorbed gases is completed, the bed is again pressurized and ready to receive and remove impurities from the portion of the mixed gas stream delivered thereto.
  • a controller that is integrated into and/or otherwise specifically associated with PSA assembly 72 is schematically indicated in FIGS. 1 and 2 at 94
  • a controller that is integrated into and/or otherwise specifically associated with fuel processing system 64 is schematically indicated in FIGS. 1 and 2 at 95
  • a controller that is in communication with at least hydrogen-generation assembly 46 to monitor and control the operation of components thereof, such as at least PSA assembly 73 and hydrogen-producing region 70 is schematically indicated at 96 .
  • the type, number, amount and form of adsorbent in a particular PSA assembly may vary without departing from the scope of the present disclosure, such as according to one or more of the following factors: the operating conditions expected in the PSA assembly, the size of the adsorbent bed, the composition and/or properties of the mixed gas stream, the desired application for the product hydrogen stream produced by the PSA assembly, the operating environment in which the PSA assembly will be used, user preferences, etc.
  • At least one heat exchanger, condenser or other suitable water-removal device may be used to cool the mixed gas stream prior to delivery of the stream to the PSA assembly. This cooling may condense some of the water present in the mixed gas stream.
  • mixed gas streams produced by steam reformers tend to contain at least 10%, and often at least 15% or more water when exhausted from the hydrogen-producing (i.e., the reforming) region of the fuel processing system. These streams also tend to be fairly hot, such as having a temperature of at least 200° C. (in the case of many mixed gas streams produced from methanol containing feedstocks), and at least 400-800° C.
  • the adsorbent(s) may be present in the bed in any suitable form, illustrative, non-exclusive examples of which include particulate form, bead form, porous discs or blocks, coated structures, laminated sheets, fabrics, and the like.
  • the adsorbents When positioned for use in the beds, the adsorbents should provide sufficient porosity and/or gas flow paths for the non-adsorbed portion of the mixed gas stream to flow through the bed without significant pressure drop through the bed.
  • the portion of a bed that contains adsorbent will be referred to as the adsorbent region of the bed.
  • an adsorbent region is indicated generally at 114 .
  • Beds 100 also may (but are not required to) include partitions, supports, screens and other suitable structure for retaining the adsorbent and other components of the bed within the compartment, in selected positions relative to each other, in a desired degree of compression, etc. These devices are generally referred to as supports and are generally indicated in FIG. 5 at 116 . Therefore, it is within the scope of the present disclosure that the adsorbent region may correspond to the entire internal compartment of the bed, or only a subset thereof. Similarly, the adsorbent region may be comprised of a continuous region or two or more spaced apart regions without departing from the scope of the present disclosure.
  • bed 100 includes at least one port 118 associated with each end region of the bed. As indicated in dashed lines, it is within the scope of the present disclosure that either or both ends of the bed may include more than one port. Similarly, it is within the scope of the disclosure that the ports may extend laterally from the beds or otherwise have a different geometry than the schematic examples shown in FIG. 5 . Regardless of the configuration and/or number of ports, the ports are collectively adapted to deliver fluid for passage through the adsorbent region of the bed and to collect fluid that passes through the adsorbent region.
  • FIG. 6 illustrates a bed 100 in which the adsorbent region extends along the entire length of the bed, i.e., between the opposed ports or other end regions of the bed
  • bed 100 includes an adsorbent region 114 that includes discontinuous subregions 120 .
  • FIG. 8 schematically illustrates potential benefits of using the startup methods and hydrogen-generation assemblies according to the present disclosure.
  • a typical startup timeline for a reformer (or other hydrogen-producing and/or hydrogen-generation assembly) and related PSA assembly is schematically illustrated. Since the reformer must be heated to a suitable (hydrogen-producing) operating temperature before it can begin to produce a product hydrogen stream in its hydrogen-producing operating state and since the PSA assembly requires a hydrogen stream before it can begin its startup sequence, the overall system startup sequence is essentially a series process, with the system waiting to begin startup of the PSA assembly until after the reformer startup is completed. Thus, the total startup time for the two assemblies may be considered to be at least the sum of the startup time for the reformer and the startup time for the PSA assembly.
  • the startup process for the PSA assembly may proceed substantially in parallel with (i.e., concurrently in time with) the startup process for the reformer.
  • the stored hydrogen gas may be used to supply the PSA assembly with hydrogen gas for its startup sequence, thereby permitting this startup sequence to occur while (or alternatively before or otherwise concurrently with) the startup sequence for the reformer assembly is proceeding.
  • the total startup time for the two assemblies may be the longer of the startup time for the reformer and the startup time for the PSA assembly. This is schematically shown in the middle timeline of FIG. 8 .
  • the startup time of both the reformer and the PSA assembly may be decreased significantly through the use of stored hydrogen gas, such as from a storage device 62 and/or purge gas source 65 , to startup the PSA assembly.
  • stored hydrogen gas such as from a storage device 62 and/or purge gas source 65
  • the purity of the product hydrogen stream leaving the PSA assembly is much higher than the purity of the product hydrogen stream leaving a PSA assembly that is started up using mixed gas stream 74 .
  • the hydrogen gas may be available for use as a combustible fuel source in temperature modulating assembly 71 used to heat hydrogen-producing region 70 .
  • this use of stored hydrogen gas to startup the PSA assembly also may provide a combustible fuel stream to assist with the startup (heating to a suitable hydrogen-producing (operating) temperature) of the hydrogen producing region, and in some embodiments may even reduce this startup time as well.
  • stored reformate gas may be used to startup the PSA assembly.
  • the startup process for the PSA assembly also may proceed partially in parallel with the startup process for the reformer, as shown in the bottom timeline of FIG. 8 .
  • the reformer startup process is begun and then, at a later time but prior to completion of the reformer startup process, the PSA assembly startup process is also begun.
  • This procedure may be used, for example, with startup techniques according to the present disclosure that do not utilize a hydrogen storage device and/or purge gas source but instead rely on the reformate stream to provide purge gas to the PSA assembly.
  • the time delay between the startup of the reformer and the startup of the PSA assembly is the time necessary to heat the reformer to a temperature at which it can begin to produce hydrogen gas.
  • the hydrogen purifying operating state of the PSA assembly has been discussed previously. A detailed discussion is now provided of illustrative, non-exclusive examples of methods that provide for rapid startup of the PSA assembly and which may be used within the scope of the present disclosure.
  • the flowchart of FIG. 9 provides an illustrative, non-exclusive example of an overall PSA assembly operating sequence 200 that may be implemented according to the present disclosure. While the method can be applied beginning at any point in the operating sequence, the following discussion begins with the PSA assembly in a hydrogen purifying (operating) state 210 . The PSA assembly continues to run in the hydrogen purifying state until it receives a command to initiate shutdown 220 . At this point, the system performs a shutdown sequence 230 and then enters a dormant state 250 . The PSA assembly remains in the dormant state until it receives a command to initiate startup 270 . The assembly proceeds to perform a startup sequence 280 and then begins running in hydrogen purifying state 210 .
  • FIGS. 10 and 11 Illustrative, non-exclusive examples of shutdown sequences 230 that may be implemented according to the present disclosure are shown in FIGS. 10 and 11 .
  • the PSA assembly is placed in a depressurized dormant state
  • the PSA assembly is placed in a pressurized dormant state.
  • depressurized dormant state it is meant that at least one of adsorbent beds 100 within PSA assembly 73 is placed at a pressure substantially at or below atmospheric pressure in preparation for the bed entering the dormant state.
  • pressurized dormant state it is meant that at least one of adsorbent beds 100 within PSA assembly 73 is placed at a pressure that is substantially above atmospheric pressure in preparation for the bed entering the dormant state.
  • This may include pressures in the range of 25-185 psia, such as pressures in the range of 35-135 psia, 35-85 psia, 85-135 psia, 55-85 psia, etc. Pressures outside of the ranges listed for both the depressurized and the pressurized dormant state are within the scope of this disclosure, as are individual pressures within these illustrative ranges.
  • PSA assembly shutdown sequence 230 includes performing a shutdown pressure cycle sequence 232 that ends with the bed being in a depressurized dormant state 250 .
  • Shutdown pressure cycle sequence 232 will be explained in more detail herein.
  • the dormant state may include the option of periodically flowing a purge gas through the PSA assembly in order to maintain a low concentration of contaminants within adsorbent beds 100 .
  • This may be accomplished, as indicated schematically at 233 , through, for example, the use of an elapsed time counter that compares the current amount of time that the PSA assembly has been in a dormant state to a threshold time, t*.
  • a threshold time t*
  • purge gas 63 from purge gas source 65 and/or optionally product hydrogen stream 66 from product hydrogen storage device 62
  • the elapsed time counter, t is reset to zero, as indicated at 237 , and the PSA assembly is placed back into the dormant state. The process may be repeated whenever the elapsed time since the last purge gas flow, t, is greater than the threshold time, t*.
  • the illustrative, non-exclusive example of a PSA assembly shutdown sequence 230 includes performing a shutdown pressure cycle sequence 232 followed by pressurizing 236 the PSA assembly to a pressure, P, between a lower threshold value, P D1 and an upper threshold value, P D2 , leaving the PSA assembly in a pressurized dormant state 250 .
  • P a pressure
  • P D1 a lower threshold value
  • P D2 an upper threshold value
  • the dormant state may include the option of using a purge gas to maintain the pressure within the PSA assembly above a threshold level, P D3 . This is accomplished at 238 through the use of a pressure comparison that compares the current pressure in the PSA assembly to the threshold pressure, P D3 . If the pressure, P, in the PSA assembly is greater than P D3 , the bed remains in a dormant state. If the pressure, P, in the PSA assembly is less than P D3 , the system proceeds to bed pressurization step 236 before returning to dormant state 250 . This cycle is repeated whenever the pressure in the PSA assembly, P, drops below the threshold pressure, P D3 .
  • the adsorbent beds 100 within PSA assembly 73 may receive other intermittent and/or continuous treatments that will facilitate a rapid startup of the PSA assembly by facilitating the desorption of residual contaminants and/or decreasing the likelihood of new contaminant adsorption.
  • the PSA assembly may be heated, Alternatively or in combination, the adsorbent beds may be placed under vacuum.
  • the methods detailed above represent only illustrative, non-exclusive embodiments.
  • time and pressure may be used to trigger a flow of gas and/or a repressurization of the PSA assembly, including but not limited to: a measured concentration of a specific gas chemistry or group of chemistries; measures of the ambient environment such as temperature, pressure, or relative humidity; time thresholds that are not constant (i.e., vary with the total amount of dormant time); or pressure thresholds that are not constant (i.e., vary with the total amount of dormant time).
  • FIG. 12 An illustrative, non-exclusive example of a shutdown pressure cycle sequence that may be implemented according to the present disclosure is shown in FIG. 12 at 240 and proceeds as follows. First, a shutdown pressure cycle counter, M, is set equal to zero at 241 . Then, the PSA assembly is pressurized to a pressure, P, between a first high pressure threshold at shutdown for cycle M, P H1SDM , and a second high pressure threshold at shutdown for cycle M, P H2SDM , at 242 .
  • the gas used to pressurize PSA assembly 73 during shutdown pressure cycle sequence 240 may come from a variety of sources, These sources may include, but are not limited to, product hydrogen stream 66 , storage device 62 , and purge gas source 65 ,
  • the bed is maintained in this pressurized state for a total of W M seconds at 244 and then depressurized to a pressure, P, between a first low pressure threshold at shutdown for cycle M, P L1SDM , and a second low pressure threshold at shutdown for cycle M, P L2SDM , at 246 .
  • the bed is maintained in this depressurized state for a total of X M seconds at 247 .
  • the pressure cycle counter, M is incremented by one at 248 .
  • a comparison is made at 249 . Depending on the result of the comparison at 249 , the system either repeats shutdown pressure cycle sequence 240 or proceeds out of the pressure cycle sequence.
  • Comparison 249 compares a current value to a desired value to determine the next step in the process. For example, if shutdown pressure cycle sequences are to be performed a total of M T times, comparison 249 compares the current value of M to M T , for example is M>M T ? If the answer is no, the desired number of pressure cycles have not been completed and the system proceeds to step 242 as shown in FIG. 12 . Alternatively, if the answer is yes, the desired number of pressure cycles has been completed and the system proceeds out of the pressure cycle sequence.
  • the shutdown pressure cycle sequences may be configured to repeat until the concentration, C, of a gas component within adsorbent beds 100 is below a threshold level, C*. In this case, comparison 249 may check that C ⁇ C* and then proceed as described above.
  • the gas component may be or include carbon monoxide, carbon dioxide, water vapor, or any other relevant contaminant or combination of contaminants found in adsorbent beds 100 .
  • comparison 249 may compare relevant parameters other than those listed, may make a differential comparison between a parameter measured in one portion of the system to a parameter measured in another portion of the system, and/or may make nested comparisons such as ensuring that a measured concentration is below a threshold level and that a desired minimum or maximum number of shutdown pressure cycles have been completed.
  • the illustrative, non-exclusive example depicted in FIG. 12 utilizes counter steps 241 and 248 , it is within the scope of the present disclosure that other methods and/or mechanisms for regulating the number of shutdown cycle sequences may be utilized. It is also with the scope of the present disclosure for the method of FIG. 12 to not utilize a predetermined number of shutdown cycle sequences, such as when comparison 249 is based on concentration C, in which case steps 241 and 249 are optional or may not be utilized,
  • each of the M bed pressurization and depressurization steps to be performed may have the same or different high pressure thresholds P H1SDM and P H2SDM , high pressure dwell times W M , low pressure thresholds P L1SDM and P L2SDM , and low pressure dwell times X M .
  • the total number of shutdown pressure cycles may be a fixed number M T or may vary based on measurements performed on PSA assembly 73 .
  • PSA assembly purge methodology may be used without departing from the scope of this disclosure, including but not limited to: pressure ramp, pressure ramp and soak, pressure cycles that follow a sinusoidal or other cyclical/periodic behavior, and/or purging at a fixed, or substantially fixed, pressure or flow rate.
  • FIG. 13 shows an illustrative, non-exclusive example of a startup pressure cycle sequence 290 that may be implemented according to the present disclosure.
  • the structure of startup pressure cycle sequence 290 is analogous to that of shutdown pressure cycle sequence 240 , with steps 291 , 292 , 294 , 296 , 297 , 298 , and 299 of the corresponding startup pressure cycle sequence corresponding generally to steps 241 , 242 , 244 , 246 , 247 , 248 , and 249 of the previously discussed shutdown pressure cycle sequence, with two noteworthy exceptions.
  • the threshold values are specific to startup pressure cycle sequence 290 .
  • P H1SUN and P H2SUN are the first and second high pressure thresholds at startup for cycle N respectively
  • Y N is the time that the bed is maintained in a pressurized state for startup cycle N
  • P L1SUN and P L2SUN are the first and second low pressure thresholds at startup for cycle N respectively
  • Z N is the time that the bed is maintained in a depressurized state for startup cycle N
  • N T is the total number of startup pressure cycles desired, if used.
  • the source of gas used to pressurize the PSA assembly may be different. Specifically, since the startup of PSA assembly 73 may proceed at least partially in parallel with the startup of hydrogen-producing region 70 , product hydrogen stream 66 or another source of hydrogen gas may not initially be available for use in charging adsorbent beds 100 with hydrogen gas.
  • the hydrogen source for the startup pressure cycle sequence may be, or may include, at least one of hydrogen storage device 62 , purge gas source 65 , or a portion of mixed gas stream 74 .
  • Use of mixed gas stream 74 as a hydrogen gas source for startup pressure cycle sequences may include using the entire mixed gas stream for pressure cycle sequences, and optionally may include using the mixed gas stream produced during reduced-output operating states of the reformer or other hydrogen generation assembly.
  • a portion of the mixed gas stream may be used for pressure cycle sequences, and a portion of the mixed gas stream may be used for other purposes, such as a fuel for heating assembly 71 .
  • any fraction of the hydrogen gas produced by the PSA assembly as product hydrogen stream 66 may then be used as a purge gas for the PSA assembly.
  • the overall time duration of pressure cycles in startup pressure cycle sequence 290 may be the same as or different from the duration of PSA pressure cycles associated with the hydrogen purifying state.
  • the startup pressure cycle sequences may be shorter than the pressure cycles associated with the hydrogen purifying state.
  • Illustrative, non-exclusive examples of shorter startup pressure cycle sequence times include times that are 5% to 95% of the corresponding hydrogen purifying state times, including times that are 30%, 40%, 50%, 60%, 70%, and/or that are in the range of 25-75%, 35-65%, or 40-60% of the corresponding hydrogen purifying state times.
  • the flow rate and overall amount of purge gas utilized during an individual startup pressure cycle may be the same as or different from the corresponding flow rate and overall volume of purge gas utilized in the hydrogen purifying state.
  • a specific fraction of product hydrogen stream 66 may be utilized as a purge gas for the PSA assembly. This may include fractions in the range of 5% to 95%, including 30%, 40%, 50%, 60%, 70%, 25-75%, 35-65%, and 40-60% of the product hydrogen stream.
  • a PSA startup pressure cycle sequence according to the present disclosure that purifies the mixed gas stream and then utilizes the resultant product hydrogen stream as a purge gas may use significantly more of the product hydrogen stream, up to and including 100% of the product hydrogen stream, as a purge gas for the PSA assembly.
  • a PSA startup pressure cycle sequence according to the present disclosure may utilize a volume of purge gas, such as up to and including 100%, 150%, 200% or more of the volume of purge gas used during the purge steps of the PSA cycle in the hydrogen purifying state.
  • the cycle time during the startup sequences may be reduced and the volume of purge gas may be increased, relative to the time and volume used by the PSA assembly during the hydrogen purifying state.
  • Flow rates and overall flows outside (i.e., greater than or less than) those listed above are also within the scope of the present disclosure and these flow rate and overall volume variations also may apply to shutdown pressure cycle sequence 240 , discussed previously.
  • FIG. 14 An illustrative, non-exclusive startup configuration for the PSA assembly is shown in FIG. 14 .
  • PSA assembly 73 is shown to be in optional fluid communication with a variety of streams. All streams are shown as optional since the specific configuration may vary with specific system installation, system design, and/or system status.
  • a substantially pure hydrogen source such as hydrogen storage device 62 and/or purge gas source 65 , may be used to charge PSA assembly 73 with hydrogen gas.
  • product hydrogen stream 66 when available, may be directed into the PSA assembly for use as a purge gas stream, as shown in the FIG. 14 .
  • mixed gas stream 74 may be unavailable or only available in limited supply due to the concurrent startup of hydrogen-producing region 70 .
  • at least one of hydrogen storage device 62 and purge gas source 65 may be used to supply substantially pure hydrogen gas to the PSA assembly at startup via PSA hydrogen delivery stream 43 and PSA purge gas supply stream 67 respectively.
  • the supplied hydrogen gas may be used to perform startup pressure cycle sequence 290 , such as previously described with respect to FIG. 13 , and then discharged from the PSA assembly via byproduct stream 76 .
  • Byproduct stream 76 may contain hydrogen gas and may have sufficient fuel value to be used as a fuel source.
  • byproduct stream 76 may be utilized in another hydrogen-consuming device or process, such as temperature modulating assembly 71 , stored for later use, or discharged from the system.
  • mixed gas stream 74 may additionally or alternatively be used to pressurize PSA assembly 73 .
  • Resultant product hydrogen stream 66 may be directed back into the PSA assembly, for use as a purge gas in performing startup pressure cycle sequence 290 , as schematically illustrated in FIG. 14 , and then discharged from the PSA assembly via byproduct stream 76 .
  • the use of mixed gas stream 74 to pressurize the PSA assembly allows the PSA assembly to produce its own purge gas and startup without the need for either hydrogen storage device 62 or purge gas source 65 .
  • a fuel processing system 64 may include both hydrogen storage device 62 and purge gas source 65 . As also shown in FIG. 14 , it is within the scope of the present disclosure that fuel processing system 64 may contain a plurality of hydrogen storage devices 62 and/or purge gas sources 65 . While the system of FIG.
  • hydrogen storage device 62 and purge gas source 65 show both hydrogen storage device 62 and purge gas source 65 as being external to fuel processing system 64 but contained within energy-producing system 22 , the specific location of hydrogen storage device 62 and purge gas source 65 is not critical or required to the details of this disclosure as long as at least one of hydrogen storage device 62 and purge gas source 65 is in fluid communication with PSA assembly 73 .
  • the pressure, P, in PSA assembly 73 refers to a representative pressure within the PSA assembly.
  • This pressure may be the average pressure in all of adsorbent beds 100 , the average pressure in one or more selected or representative adsorbent beds 100 , the pressure in an individual adsorbent bed 100 , the minimum pressure from a series of pressure measurements within all or select adsorbent beds 100 , the maximum pressure from a series of pressure measurements within all or select adsorbent beds 100 , the pressure in distribution assembly 102 or 104 , a differential pressure measurement, or any other pressure that is selected as representative of the pressure within the entire PSA assembly or within components thereof.
  • a method refers to pressurizing and/or depressurizing PSA assembly 73
  • the PSA assembly will typically include two or more adsorbent beds 100 and that, depending on the system configuration, it may or may not be possible and/or desirable to pressurize and/or depressurize all of the adsorbent beds simultaneously.
  • a step involving pressurizing or depressurizing the PSA assembly may involve pressurizing or depressurizing all adsorbent beds and associated distribution assemblies at one time or it may involve sequential pressurization or depressurization of individual components.
  • one or more of a plurality of adsorbent beds within the PSA assembly may not receive the same pressurization or depressurization treatment as other beds within the PSA assembly. This may be true if, for example, the PSA assembly is constructed of a relatively large number of adsorbent beds and it is not necessary to provide a rigorous shutdown, dormant, and startup treatment to all beds in order to ensure the rapid availability of the PSA assembly as a whole upon system startup.
  • a PSA assembly controller which may form a portion of a hydrogen-generation assembly and/or energy-producing system according to the present disclosure, may be adapted to detect a parameter related to the status of a particular adsorbent bed 100 within PSA assembly 73 and be configured to selectively change the order in which individual adsorbent beds 100 are transitioned from a startup state to a hydrogen-purifying state based on the detected status.
  • the PSA assembly controller may detect the concentration of carbon monoxide, carbon dioxide, water, or another relevant contaminant within individual adsorbent beds 100 and selectively transition the beds from a startup state to a hydrogen-purifying state once the concentration is below a threshold level.
  • the illustrative, non-exclusive examples and methods described above may be utilized individually via shutdown, dormant, and/or startup treatments that will minimize the overall startup time of the hydrogen-generation assembly; however they also may be utilized in combination and/or with other methods and/or treatments.
  • the PSA startup sequences are frequently described herein as being performed substantially in parallel with (or concurrently with) the startup of the hydrogen-producing region through the use of stored purge gas source 62 or 65 , it is within the scope of the present disclosure that reformate from the hydrogen-producing region may be used to charge the PSA assembly at startup,
  • the following illustrative, non-exclusive examples describe combination methods that may be utilized to minimize the startup time of the PSA assembly.
  • product hydrogen stream 66 is used to perform shutdown cycling and remove contaminants from the PSA assembly.
  • the PSA assembly is pressurized with product hydrogen stream 66 to place the PSA assembly in a pressurized dormant state.
  • startup cycling is performed using (substantially pure) hydrogen gas from either or both of storage device 62 or purge gas source 65 .
  • product hydrogen stream 66 is used to perform shutdown cycling and remove contaminants from the PSA assembly.
  • the PSA assembly is placed in a depressurized dormant state.
  • startup cycling is performed using (substantially pure) hydrogen gas from either or both of storage device 62 or purge gas source 65 .
  • purified hydrogen gas from a hydrogen storage device such as which contained purified hydrogen gas produced by the fuel processing system prior to shutdown of a prior operating state thereof
  • the concentration of carbon dioxide exiting the PSA assembly was less than 2 ppm (parts per million).
  • product hydrogen stream 66 is used to perform shutdown cycling and remove contaminants from the PSA assembly.
  • the PSA assembly is pressurized with product hydrogen stream 66 to place the PSA assembly in a pressurized dormant state.
  • startup cycling is performed using reformate gas produced by the hydrogen-producing region of the hydrogen-generation assembly.
  • product hydrogen stream 66 is used to perform shutdown cycling and remove contaminants from the PSA assembly,
  • the PSA assembly is placed in a depressurized dormant state.
  • startup cycling is performed using reformate gas produced by the hydrogen-producing region of the hydrogen-generation assembly.
  • shortened shutdown and startup sequences, or cycles, were performed, such as provided for herein in which reformate gas was used for the shortened startup cycles. Due to the reformate stream being delivered while startup of the reformer also was occurring, the pressure of this stream increased over time to a desired delivery pressure, such as 80 psig.
  • the concentration of carbon monoxide was less than 2 ppm, While longer than the experiments performed in accordance with Example 2, the time is still noticeably less than if the reformer and PSA assembly were started up sequentially, or in series.
  • product hydrogen stream 66 is used to perform reduced cycle time shutdown pressure cycling and remove contaminants from the PSA assembly.
  • the overall PSA shutdown cycle time is 50% of the cycle time associated with the hydrogen purifying state and 100% of the product hydrogen stream is utilized as a purge gas for the PSA assembly.
  • Individual PSA adsorbent beds 100 are purged and cleaned sequentially such that, as one bed is producing hydrogen gas, the next bed is being purified by the produced hydrogen gas.
  • the PSA assembly is then placed in a depressurized dormant state.
  • an adsorbent bed is charged with mixed gas stream 74 , when it becomes available.
  • this Example may be used in conjunction with a PSA assembly that was shutdown according to Example 5, and further optionally, the last adsorbent bed to be purged during the shutdown pressure cycle is the first adsorbent bed to be charged with mixed gas stream 74 .
  • reduced cycle time startup pressure cycling is performed in which the cycle time is 50% of the cycle time associated with the hydrogen purifying state, 100% of the product hydrogen stream is utilized as a purge gas for the PSA assembly, and the beds are purged sequentially, with the product hydrogen gas produced by one bed being used to purge the next bed in series. The cycle is repeated until a desired number of cycles have been completed and/or the concentration of contaminants in the product hydrogen stream is below a threshold level.
  • the term “and/or” placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity.
  • Multiple entities listed with “and/or” should be construed in the same manner, i.e., “one or more” of the entities so conjoined.
  • Other entities may optionally be present other than the entities specifically identified by the “and/or” clause, whether related or unrelated to those entities specifically identified.
  • a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” may refer, in one embodiment, to A only (optionally including entities other than B); in another embodiment, to B only (optionally including entities other than A); in yet another embodiment, to both A and B (optionally including other entities).
  • These entities may refer to elements, actions, structures, steps, operations, values, and the like.
  • the phrase “at least one,” in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entity in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities.
  • This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase “at least one” refers, whether related or unrelated to those entities specifically identified.
  • “at least one of A and B” may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities).
  • each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B and C together, and optionally any of the above in combination with at least one other entity.
  • any of the references that are incorporated by reference herein define a term in a manner or are otherwise inconsistent with either the non-incorporated portion of the present disclosure or with any of the other incorporated references, the non-incorporated portion of the present disclosure shall control, and the term or incorporated disclosure therein shall only control with respect to the reference in which the term is defined and/or the incorporated disclosure was originally present.
  • a method for starting up a hydrogen-generation assembly that includes a hydrogen-producing region (HPR) and a pressure swing adsorption (PSA) assembly, the hydrogen-producing region having HPR hydrogen-producing, HPR shutdown, HPR dormant, and HPR startup states, the PSA assembly having PSA hydrogen-purifying, PSA shutdown, PSA dormant, and PSA startup states, and the PSA assembly further having an internal pressure, the method comprising:
  • utilizing the PSA startup sequence includes utilizing the PSA startup sequence at least partially concurrently with the HPR startup sequence.
  • a method for starting up a hydrogen-generation assembly that includes a hydrogen-producing region (HPR) and a pressure swing adsorption (PSA) assembly, the hydrogen-producing region having HPR hydrogen-producing, HPR shutdown, HPR dormant, and HPR startup states, the PSA assembly having PSA hydrogen-purifying, PSA shutdown, PSA dormant, and PSA startup states, and the PSA assembly further having an internal pressure, the method comprising:
  • utilizing a HPR startup sequence to transition the HPR from the HPR dormant state to the HPR hydrogen-producing state and utilizing a PSA startup sequence to transition the PSA assembly from the PSA dormant state to the PSA hydrogen-purifying state wherein at least the PSA startup sequence includes supplying hydrogen gas to the PSA assembly from a hydrogen source, and further wherein the utilizing the PSA startup sequence includes utilizing the PSA startup sequence at least partially concurrently with the HPR startup sequence.
  • the heat source includes one or more of an electric heater, a reformer exhaust stream, a fuel cell stack coolant stream, a hot air stream from a cabinet heater, another heat source associated with the fuel cell system, and another external heat source available to the fuel cell system.
  • the PSA shutdown sequence includes performing at least one purge cycle that involves supplying a purge gas stream to the PSA assembly to increase the internal pressure of the PSA assembly to a first pressure, maintaining the internal pressure at the first pressure for a first time period, decreasing the internal pressure of the PSA assembly to a second pressure by discharging gas within the PSA assembly to a byproduct stream, maintaining the internal pressure at the second pressure for a second time period; and
  • the PSA startup sequence includes performing at least one purge cycle that involves supplying the startup hydrogen stream to the PSA assembly to increase the internal pressure of the PSA assembly, maintaining the internal pressure for a time period, decreasing the internal pressure of the PSA assembly by discharging gas within the PSA assembly to a byproduct stream, maintaining the internal pressure for a further time period;
  • the PSA startup sequence includes performing at least one purge cycle that involves supplying the startup hydrogen stream to the PSA assembly to increase the internal pressure of the PSA assembly to a third pressure, maintaining the internal pressure at the third pressure for a fourth time period, decreasing the internal pressure of the PSA assembly to a fourth pressure by discharging gas within the PSA assembly to a byproduct stream, maintaining the internal pressure at the fourth pressure for a fifth time period;
  • a hydrogen-producing system configured to utilize the methods of any of paragraphs A1-B56.
  • HPR hydrogen-producing region
  • PSA pressure swing adsorption
  • Control means for controlling at least one of startup and shutdown of a hydrogen-generation assembly utilizing the method of any of paragraphs A1-B56.
  • a controller configured to control at least one of startup and shutdown of a hydrogen-generation assembly utilizing the method of any of paragraphs A1-B56.
  • controller of paragraph E2 wherein the controller is a computer-implemented controller.
  • a fuel processing system with a hydrogen-producing region adapted to produce from a feedstock supply stream a mixed gas stream containing hydrogen gas as a majority component and other gases as minority components;
  • a hydrogen source other than the hydrogen-producing region and the PSA assembly fluidly connected to the PSA assembly and configured to provide hydrogen gas to the PSA assembly during startup of the PSA assembly.
  • the hydrogen-generation assembly of any of paragraphs F1-F9 further comprising a controller configured to control operation of at least one of, and optionally both of, the fuel processing system and the PSA assembly.
  • the hydrogen-generation assembly of claim F10 wherein the controller is configured to shutdown at least one of, and optionally both of, the fuel processing system and the PSA assembly to a dormant state.
  • the methods for rapid startup of pressure swing adsorption assemblies and hydrogen-generation and/or fuel cell systems including the same are applicable in the gas generation and fuel cell fields, including such fields in which hydrogen gas is generated, purified, and/or consumed to produce an electric current.

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